Temperature sensor for coolant control valve

ABSTRACT

A coolant control valve includes an actuator, at least one valve body, an outer housing, and a temperature sensor having a first flow state and a second flow state. The first and second flow states can be achieved by first and second axial positions of the temperature sensor.

TECHNICAL FIELD

Example aspects described herein relate to coolant control valves (CCVs)for use within fluid cooling systems.

BACKGROUND

CCVs are known and can be arranged to provide coolant flow control fortemperature management of various powertrain components including ICengines, transmissions and various components of hybrid electric andfuel cell vehicles.

A portion of CCVs are electro-mechanical in design, incorporating anelectrical actuator assembly that interfaces with a mechanical valvebody to provide a controlled flow of coolant for a selected powertraincomponent or system. Depending on its design, the mechanical valve bodycan be linearly actuated or rotary actuated by an actuator, often timesin the form of an electric motor or solenoid. The valve body can beconfigured with one or more fluid openings that control an amount ofcoolant flow to or from one or more inlets or outlets arranged on anouter housing of the coolant control valve. Electro-mechanical CCVs canoffer continuously variable positions of the valve body to achievevarious coolant flow rates. Like many other electronic controlled enginecomponents, a fail-safe design feature is required that facilitates safeoperation of the engine in the event of a functional failure of the CCV.

SUMMARY

A CCV is provided that includes an actuator, at least one valve bodyactuated by the actuator, an outer housing, and a temperature sensorhaving a first flow state and a second flow state; the first flow statecan be a zero flow state and the second flow state can be a non-zeroflow state. The outer housing includes at least one inlet and at leastone outlet. A seal can be arranged between the temperature sensor andthe outer housing. The actuator can be configured to be providedelectronic communication from an electronic controller to move the atleast one valve body to a selected one of any angular position within acontinuous range of angular positions. The temperature sensor cancommunicate electronically with the electronic controller to provide afluid temperature.

The temperature sensor can have a displaceable body capable of a firstaxial position that corresponds to the first flow state, and a secondaxial position that corresponds to the second flow state. While in thesecond axial position, a passageway can be formed that connects an innerchamber of the coolant control valve to one of the at least one outlet,which can be in fluid communication with a fluid reservoir. Thetemperature sensor can be disposed directly within an outer housing orwithin an end-cap or any other component that attaches to the outerhousing.

The temperature sensor can have a first force generator, potentiallyformed as a spring, which applies a biasing force to the displaceablebody in a first axial direction. The temperature sensor or displaceablebody is configured to receive an actuation force that overcomes thebiasing force to achieve the second axial position. The actuation forcecan be provided by a pressurized fluid that contacts the temperaturesensor. The actuation force can also be provided by a second forcegenerator configured as a temperature sensor. The second force generatorcan include a wax material that expands with increasing temperature. Thesecond force generator can include a rod that is configured to move thedisplaceable body, the rod displaceable by the wax material. The waxmaterial can have a first temperature while in the first axial position,and a second temperature while in the second axial position, the secondtemperature greater than the first.

A method of operating a CCV is provided that includes: 1). Flowingpressurized fluid through a CCV that is configured with a temperaturesensor; 2). Generating an actuation force that acts upon the temperaturesensor, a displaceable body of the temperature sensor subjected to abiasing force in a first axial direction by a first force generator; 3).Overcoming the biasing force with the actuation force; and, 4). Movingthe displaceable body in a second axial direction to a position thatforms a passageway that fluidly connects an inner chamber of the CCV toan outlet. The generating an actuation force step can be provided byeither a second force generator or a pressurized fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

The above mentioned and other features and advantages of the embodimentsdescribed herein, and the manner of attaining them, will become apparentand better understood by reference to the following descriptions ofmultiple example embodiments in conjunction with the accompanyingdrawings. A brief description of the drawings now follows.

FIG. 1 is a perspective view of a coolant control valve (CCV) having anexample embodiment a temperature sensor with a first flow state and asecond flow state.

FIG. 2 is a partially exploded perspective view of the CCV of FIG. 1.

FIG. 3 is a perspective view of the temperature sensor and housingportion of FIG. 1.

FIG. 4A is a partial cross-sectional view of the CCV of FIG. 1, showingthe temperature sensor in a first flow state.

FIG. 4B is a partial cross-sectional view of the CCV of FIG. 1, showingthe temperature sensor in a second flow state.

FIG. 5 is a side view of an example embodiment of a second forcegenerator for temperature sensor actuation.

FIG. 6A is a partial cross-sectional view of an example embodiment of atemperature sensor disposed within a CCV housing, the temperature sensorin a first flow state.

FIG. 6B is a partial cross-sectional view of an example embodiment of atemperature sensor disposed within a CCV housing, the temperature sensorin a second flow state.

FIG. 7 is a schematic representation of a CCV together with anelectronic controller and a coolant reservoir.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Identically labeled elements appearing in different figures refer to thesame elements but may not be referenced in the description for allfigures. The exemplification set out herein illustrates at least oneembodiment, in at least one form, and such exemplification is not to beconstrued as limiting the scope of the claims in any manner. Certainterminology is used in the following description for convenience onlyand is not limiting. The words “inner,” “outer,” “inwardly,” and“outwardly” refer to directions towards and away from the partsreferenced in the drawings. Axially refers to directions along adiametric central axis. Radially refers to directions that areperpendicular to the central axis. Circumferentially refers to an outerboundary of a circle or curve. The words “left” and “right” designatedirections in the drawings to which reference is made. The terminologyincludes the words specifically noted above, derivatives thereof, andwords of similar import.

FIG. 1 shows a perspective view of a coolant control valve (CCV) 10 thatincludes a temperature sensor 20 having a first flow state and a secondflow state. FIG. 2 shows an exploded perspective view of the CCV 10 ofFIG. 1. FIG. 3 shows a perspective view of the temperature sensor 20installed within an end-cap 60 that is arranged on an outer housing 12of the CCV 10. FIG. 4A is a partial cross-sectional view of the CCV 10,showing the temperature sensor 20 in a first axial position thatcorresponds to a first flow state, while FIG. 4B is a partialcross-sectional view of the CCV 10, showing the temperature sensor in asecond axial position that corresponds to a second flow state. FIG. 5 isa side view of an example embodiment of a second force generator 80 foractuation of the temperature sensor 20. The following discussion shouldbe read in light of FIGS. 1 through 5.

The outer housing 12 of the CCV 10 is configured to be attached to an ICengine (not shown) via one or more mounting feet 13. Other designs orfeatures that facilitate attachment of the CCV 10 could also suffice.Additionally, the CCV 10 does not have to attach to an IC engine, butcan be attached to any receiving structure or mounting base. The outerhousing 12 is configured with openings 14A-14D, which can serve aseither inlets or outlets for the CCV 10. Coolant flow within each of theopenings 14A-14D is managed by a valve body 18 that is disposed withinthe outer housing 12. The valve body 18 can be formed with one or morespherical segments and can be configured with at least one fluid opening19; however, any shape can be utilized for the valve body 18 tofacilitate fluid flow control. The amount of fluid flow through theopenings 14A-14D can be controlled by rotational actuation of the valvebody 18 by an actuator assembly 16. The actuator assembly 16 can have,for example, an electric motor 17 that rotates the valve body 18 to adesired angular or rotational position. Other actuator designs,including linear actuators, are possible. In an example embodiment, theactuator assembly 16 can move the valve body 18 to a selected one of anyangular position within a continuous range of angular positions;alternatively stated, the angular position of the valve body 18 iscontinuously variable. An amount of coolant flow through any one of theopenings 14A-14D is controlled by an amount of overlap between the atleast one fluid opening 19 and its respective opening 14A-14D in theouter housing 12.

The temperature sensor 20 is disposed within the outer housing 12, or,more specifically, the end-cap 60 of the outer housing 12. Thetemperature sensor 20 could be located anywhere within or on the outerhousing 12 or any component that is attached to the outer housing 12.The phrase “disposed within the outer housing 12” is meant to signifyany location within or on the outer housing 12 or any component thatattaches to the outer housing 12. The temperature sensor 20 includes acentral axis 2, an electrical connector 22, at least one temperaturesensing element 31, a first force generator 30, a displaceable body 24,and a retention clip 40. The electrical connector facilitates electroniccommunication between the temperature sensor 20 and an electroniccontroller 90 (shown in FIG. 7). In addition to providing temperaturefeedback, the temperature sensor 20 is capable of moving axially alongthe central axis 2 to achieve different flow states. FIG. 4A depicts afirst axial position that corresponds to a first flow state, and FIG. 4Bdepicts a second axial position that corresponds to a second flow state.The first flow state can be a zero flow state and the second flow statecan be a non-zero flow state. Many different sealing arrangements arepossible to facilitate sealing of the temperature sensor 20 to theend-cap 60 that is attached to the outer housing 12. As shown, thedisplaceable body 24 of the temperature sensor 20 is received by anoptional motion guide 38 that may either be integrated with thetemperature sensor 20 or provided as a separate component that isinstalled within a sensor bore 36 of the end-cap 60; the optional motionguide 38 could also be installed within a sensor bore that is integratedwithin the outer housing 12, potentially eliminating the end-cap 60. Aradial seal 26 can be arranged within the sensor bore 36, and an axialseal 28 can be arranged between an axial face 45 of the motion guide 38and an axial face 46 of the displaceable body 24. The first forcegenerator 30 provides a biasing force F1 on the displaceable body 24 ina first axial direction A1, as shown in FIG. 4A, such that the axialseal 28 prevents coolant flow from exiting the CCV 10, achieving a zeroflow state. The first force generator 30 can be formed as a spring (asshown), resilient element, or any other component that provides a force.

A second force generator 80 can be integrated either within the outerhousing 12, the motion guide 38 or any other component within thetemperature sensor 20. The second force generator 80 can provide anactuation force F2 that acts on the displaceable body 24 in a secondaxial direction A2; when the actuation force F2 exceeds the biasingforce F1 of the first force generator 30, the displaceable body 24 movesto the second axial position. Referring to FIG. 4B, in this second axialposition, a passageway 50 is formed by the displaceable body 24 thatfluidly connects an inner chamber 32 of the CCV 10 to an outlet 15arranged within the outer housing 12.

An example embodiment of the second force generator 80 is shown in FIG.5 with hidden lines for clarity of its inner components. The secondforce generator 80 includes a rod 82 that is actuatable by a waxmaterial 86. The volume of wax material increases with temperature,therefore, as temperature increases, the actuation force F2 generated bythe rod increases. Given this characteristic of wax and its presencewithin the second force generator 80, it could be stated that the secondforce generator 82 is also a temperature sensor. An actuatable end 85 ofthe rod 82 is configured with an enlarged portion 84 that interfaceswith the wax material 86. Many different forms of the housing 88 arepossible in order to package the second force generator 80 within theouter housing 12 of the CCV 10. Furthermore, other forms of the secondforce generator 80 are possible than what is shown in FIG. 5.

Referring to FIG. 4A through FIG. 5, the function of the second forcegenerator 80 will now be described. With view to FIG. 4A, a fluid 52with a first temperature T1 resides within the outer housing 12 andflows around the second force generator 80 with the aid of first fluidapertures 34A, 34B, facilitating convective heat transfer from the fluid52 to the second force generator 80 and its internal components. Thefluid 52 can be engine coolant or any other fluid that flows through theCCV 10. In the first axial position, the second force generator 80provides a force F2A that is less than the biasing force F1 of the firstforce generator 30; therefore, the displaceable body 24 of thetemperature sensor 20 remains in a seated position. In this first axialposition, the axial seal 28 prevents the fluid 52 from exiting the CCV10 through the outlet 15, achieving a zero flow state.

Now referring to FIG. 4B with view to FIG. 5, the second axial positionof the temperature sensor 20 is shown. The fluid 52 with a secondtemperature T2 circulates around the second force generator 80, causingthe wax material 86 to expand and actuate the rod 82 in the second axialdirection A2 with a force F2B that exceeds the biasing force F1 of thefirst force generator 30. The rod 82 moves the displaceable body 24 ofthe temperature sensor 20 in the second axial direction A2 forming apassageway 50 that fluidly connects the inner chamber 32 of the CCV 10to the outlet 15; thus, the second axial position achieves a non-zeroflow state for the fluid 52 flowing through the outlet 15. Furthermore,a fluid within the outer housing 12 can take a pathway P1 to exit theouter housing 12 in an instance of excessive fluid temperatures beingpresent inside of the CCV 10. The fluid pathway P1 can include firstfluid apertures 34A, 34B that are configured within a bottom portion 47of the motion guide 38 and second fluid apertures 39A, 39B that areconfigured within a top portion 49 of the motion guide 38.

Systematic calibration of the second force generator 80 and the firstforce generator 30 can be achieved such that the actuation force F2 ofthe second force generator 80 exceeds the biasing force F1 of the firstforce generator 30 at a critical temperature Tcr of the fluid 52,facilitating axial movement of the displaceable body 24 in the secondaxial direction A2. The critical temperature Tcr could be a temperaturethat is harmful to the CCV 10 or any component whose temperature isbeing managed by the CCV 10. A mathematical formula representing thisrelationship is shown below:If T≥Tcr, then F2>F1

Where: T=temperature of fluid 52

Tcr=critical temperature of fluid 52

F1=force provided by first force generator 30

F2=force provided by second force generator 80

FIGS. 6A and 6B show an example embodiment of a temperature sensor 20′in respective first and second axial positions. The temperature sensor20′, installed within an end-cap 60′ arranged on the outer housing 12 ofa CCV 10′, includes a central axis 2′, a displaceable body 24′, a firstforce generator 30′, a housing 48, and an axial seal 28′. The firstforce generator 30′ applies a biasing force F1′ on the displaceable body24′ in the first axial direction A1. For this example embodiment, anactuation force F2′ to move the temperature sensor 20′ to its secondaxial position is provided by pressurized fluid.

Referring to FIG. 6A, the first axial position of the temperature sensor20′ is shown. A fluid 52′ with pressure Pr1 circulates against a housing48 of the temperature sensor 20′, providing a resultant actuation forceF2A′ acting in a second axial direction A2 on the housing 48. Firstfluid apertures 44A, 44B formed in the end-cap 60′ can facilitateincreased circulation of the fluid 52′, and, thus, contact area of thehousing 48 by the fluid 52′; however, these first fluid apertures 44A,44B but could be eliminated. The fluid 52′ could also circulate orcontact directly on the displaceable body 24′ or any other component ofthe temperature sensor 20′. In the first axial position, the resultantactuation force F2A′ does not exceed the biasing force F1′ provided bythe first force generator 30′, and an axial seal 28′ arranged betweenthe housing 58 and the end-cap 60′ prevents any fluid from exiting theCCV 10′ through an outlet 15′.

Referring to FIG. 6B, the second axial position of the temperaturesensor 20′ is shown, in which a resultant actuation force F2B′ createdby the fluid 52′ at a pressure Pr2 on the housing 48 exceeds the biasingforce F1′ of the first force generator 30′. In this second axialposition, a passageway 50′ is formed by the displaceable body 24′ thatfluidly connects the inner chamber 32′ of the CCV 10′ to the outlet 15′.Therefore a fluid within the outer housing 12 can take a pathway PW1′ toexit the outer housing 12 in an instance of excessive fluid pressuresbeing present inside of the CCV 10′. The fluid pathway PW1′ can includefirst fluid apertures 44A, 44B that are formed in the end-cap 60′. Manyalternative designs for the temperature sensor 20′ are possible,including those that eliminate the housing 48 such that the fluid 52directly contacts the displaceable body 24′. Additional designmodifications could facilitate installation of the temperature sensor20′ at a different location on the outer housing 12, or potentially onanother component that attaches to the outer housing besides the end-cap60′.

A method of operating the previously described CCVs 10, 10′ is providedthat includes: 1). Flowing pressurized fluid through a CCV 10, 10′ thatis configured with a temperature sensor 20, 20′; 2). Generating anactuation force F2, F2′ that acts upon the temperature sensor 20, 20′, adisplaceable body 24, 24′ of the temperature sensor 20, 20′ subjected toa biasing force F1, F1′ in a first axial direction A1 by a first forcegenerator 30, 30′; 3). Overcoming the biasing force F1, F1′ with theactuation force F2B, F2B′; and, 4). Moving the displaceable body 24, 24′in a second axial direction A2 to a position that forms a passageway 50,50′ that fluidly connects an inner chamber 32, 32′ of the CCV 10, 10′ toan outlet 15, 15′. The generating an actuation force step can beprovided by either a second force generator 80 or a pressurized fluid52′.

FIG. 7 shows a schematic representation of the CCV 10, 10′ together withan electronic controller 90 and a fluid receiver or fluid reservoir 95.The electronic controller 90 can communicate electronically with thetemperature sensor 20, 20′ and also communicate electronically with theCCV 10, 10′ to control fluid flow to or from the CCV 10, 10′. The fluidreceiver or fluid reservoir 95 can be fluidly connected to an outlet 15,15′ of the CCV 10, 10′ to serve as a storage place for fluid that hasbeen expelled from the CCV 10, 10′ due to an excessive fluid temperatureor excessive fluid pressure condition.

The temperature sensor 20, 20′ can provide an additional fail-safe modein addition to sensing and communicating fluid temperature. Thisfail-safe mode can prevent component or engine failure due to anexcessive fluid temperature or pressure within the CCV 10, 10′. However,the described axial positions and corresponding flow states can also beutilized in a non-fail-safe manner to provide additional functions forthe CCV 10, 10′. For example, the second axial position of thetemperature sensor 20, 20′ could be achieved by a non-criticaltemperature or a non-critical pressure of the fluid 52, 52′ within theCCV 10, 10′. Furthermore, in the second axial position, fluid 52, 52′could exit the CCV 10, 10′ and flow to any fluid receiver, such as acomponent or system.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms encompassed by the claims.The words used in the specification are words of description rather thanlimitation, and it is understood that various changes can be madewithout departing from the spirit and scope of the disclosure. Aspreviously described, the features of various embodiments can becombined to form further embodiments that may not be explicitlydescribed or illustrated. While various embodiments could have beendescribed as providing advantages or being preferred over otherembodiments or prior art implementations with respect to one or moredesired characteristics, those of ordinary skill in the art recognizethat one or more features or characteristics can be compromised toachieve desired overall system attributes, which depend on the specificapplication and implementation. These attributes can include, but arenot limited to cost, strength, durability, life cycle cost,marketability, appearance, packaging, size, serviceability, weight,manufacturability, ease of assembly, etc. As such, to the extent anyembodiments are described as less desirable than other embodiments orprior art implementations with respect to one or more characteristics,these embodiments are not outside the scope of the disclosure and can bedesirable for particular applications.

What we claim is:
 1. A coolant control valve comprising: an actuator; at least one valve body actuated by the actuator; an outer housing having: at least one inlet; and, at least one outlet; and, a temperature sensor having: a displaceable body movable to: i) a first axial position corresponding to a zero flow state, and ii) a second axial position corresponding to a non-zero flow state, the displaceable body including: a force generator; an electrical connector; and, a temperature sensing element configured to provide a fluid temperature to an electronic controller via the electrical connector.
 2. The coolant control valve of claim 1, further comprising a seal arranged between the temperature sensor and the outer housing.
 3. The coolant control valve of claim 1, wherein the actuator is configured to move the at least one valve body to a selected one of any angular position within a continuous range of angular positions.
 4. The coolant control valve of claim 1, wherein in the second axial position a passageway is formed that fluidly connects an inner chamber of the coolant control valve to one of the at least one outlet.
 5. The coolant control valve of claim 1, wherein the force generator provides a biasing force on the displaceable body in a first axial direction.
 6. The coolant control valve of claim 5, wherein the temperature sensor is configured to receive an actuation force that overcomes the biasing force to achieve the second axial position.
 7. The coolant control valve of claim 6, wherein the actuation force is provided by a pressurized fluid that contacts the temperature sensor.
 8. The coolant control valve of claim 6, wherein the actuation force is provided by a second temperature sensor.
 9. The coolant control valve of claim 8, wherein the second temperature sensor comprises a wax material.
 10. The coolant control valve of claim 9, wherein the second temperature sensor further comprises a rod that is configured to move the displaceable body, the rod axially displaceable by the wax material.
 11. The coolant control valve of claim 9, wherein the wax material has a first temperature while in the first axial position, and a second temperature while in the second axial position, the second temperature greater than the first temperature.
 12. A method of operating a coolant control valve, comprising: flowing pressurized fluid through the coolant control valve, the coolant control valve comprising a first temperature sensor having a displaceable body, the displaceable body including: an electrical connector; and, a temperature sensing element configured to provide a fluid temperature of the pressurized fluid to an electronic controller via the electrical connector; generating an actuation force that acts upon the first temperature sensor, the displaceable body of the first temperature sensor subjected to a biasing force in a first axial direction by a first force generator; overcoming the biasing force with the actuation force; and, moving the displaceable body in a second axial direction to a position that forms a passageway that fluidly connects an inner chamber of the coolant control valve to an outlet.
 13. The method of claim 12, wherein the generating an actuation force step is provided by the pressurized fluid.
 14. The method of claim 12, wherein the generating an actuation force step is provided by a second temperature sensor.
 15. A coolant control valve comprising: an actuator; at least one valve body actuated by the actuator; an outer housing having: at least one inlet; and, at least one outlet; and, a temperature sensor having: a first temperature sensor configured to electronically communicate a temperature to an electronic controller, the first temperature sensor having a first flow state and a second flow state; and, a second temperature sensor configured to actuate the first temperature sensor to the first or second flow state.
 16. The coolant control valve of claim 15, wherein in the second flow state, a passageway is formed between the first temperature sensor and the outer housing, the passageway fluidly connecting an inner chamber of the coolant control valve to one of the at least one outlet. 